Chemical Engineering April 2020 - 31

all solid materials are capable of agglomeration
by pressure.
Primary steps
A typical pelletizing process setup
is illustrated in Figure 3. While processes
can vary, the most common
approach to pelletizing can be broken
down into three primary steps: preconditioning,
pelletizing and drying.
Preconditioning. A preconditioning
step is used to produce a homogeneous
mixture of a dry or liquid binder
and one or multiple feedstocks. It
can also produce " seed pellets, " or
nuclei - small agglomerates that
serve as the starting particle mass
onto which fines will adhere.
Preconditioning is carried out in
an industrial continuous mixer, most
often a pin mixer - a horizontal, continuous
mixer that uses an intense
spinning motion to homogeneously
pre-mix, densify, and possibly preform
small agglomerates (Figure 4).
The mixer thoroughly combines
the liquid and solid feed components
into a homogeneous mixture.
As the mixture moves down
the length of the mixer, seed pellets
begin to form. Upon reaching the
predetermined retention time, seed
pellets and preconditioned fines are
discharged from the mixer and fed
to the disc pelletizer.
Pelletizing. The disc pelletizer is a rotating
disc mounted onto a stationary
FIGURE 6. Rotary dryers remove moisture from the agglomerated solids, allowing them to reach the desired
crush strength
base (Figure 5). It is one of the most
commonly used types of pelletizing
equipment, because it produces a refined
granule and offers a highly flexible
approach to pelletizing. A number
of variables, such as disc angle,
speed, feed rate and others, can all
be adjusted to control particle size
and other characteristics.
As the seed pellets are fed onto
the rotating disc, the rotation carries
pellets partially around the disc and
through the feed and spray zones.
The binder causes the growing pellets
to become tacky, allowing them
to pick up more fines as they tumble.
This promotes a gradual rolling action
that increases granule size by
layering (coalescence) - a technique
similar to rolling a snowball.
Because of the centrifugal force
of the rotating disc, pellets naturally
self-classify according to mass and
size, with larger and heavier pellets
falling sooner as they move closer to
the discharge area. Once the pellets
have reached the desired size, they
are discharged from the disc and fed
to a dryer.
Drying. Depending on the process
goals and downstream processing,
drying may or may not be used in
a pelletizing process. The primary
objective of drying is to reduce the
moisture content of the material and
solidify the bond between compoFor
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APRIL 2020
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Chemical Engineering April 2020

Table of Contents for the Digital Edition of Chemical Engineering April 2020

Contents
Chemical Engineering April 2020 - Cover1
Chemical Engineering April 2020 - Cover2
Chemical Engineering April 2020 - Contents
Chemical Engineering April 2020 - 2
Chemical Engineering April 2020 - 3
Chemical Engineering April 2020 - 4
Chemical Engineering April 2020 - 5
Chemical Engineering April 2020 - 6
Chemical Engineering April 2020 - 7
Chemical Engineering April 2020 - 8
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Chemical Engineering April 2020 - Cover3
Chemical Engineering April 2020 - Cover4
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